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engineering
materials science engineering
Materials and process in manufacturing 9th edition E. Paul DeGarmo, J T. Black, Ronald A. Kohser - Solutions
What is the difference between production control and inventory control?
How does the design of the product influence the design of the manufacturing system, including assembly and the production system?
Discuss this statement: "Software can be as costly to design and de-velop as hardware and will require long production runs to recover, even though these costs may be hidden in the overhead costs"
Suppose that the part in Figure 41-20 was to be made in quantities of 250 rather than 25. What processes and machines would you have selected?
Explain the difference between a route sheet and an opera¬tions sheet (or a process planning sheet).
What does the study of ergonomics entail? (This was not discussed in Chapter 41.)
How does the mrp use the BOM and the MPS to determine how many of an item should be ordered?
Define CIM in your own words.
a. What is a route sheet? b. What is the function of a route sheet? c. Find an example of a route sheet other than the one in the book. d. What are other names for a route sheet?
What is a process flow chart? How is it related to the bill of material?
What is an operations sheet? How is it related to the route sheet?
What is MRP and how is it related (tied to) the MPS?
How is the EOQ calculation used in MRP?
a. What is the function of inventory control? b. How are inventory levels controlled?
What is takt time? Discuss.
If a machine's processing time exceeds cycle time in a manufacturing cell, what after natives might the manufacturing engineer consider to ensure that a cell meets the necessary cycle time?
Why is single-piece flow necessary?
Identify the machine design requirements for cells (for example, a walkaway switch).
a. Assume that the takt time is 60 seconds for a cell, but a finishing process has a cycle time of 65 seconds, and there is no way known to reduce that time. What would you do, ideally, and why? b. If a new finishing process machine costs $5,000, what would you do? c. If a new machine costs
a. What is a mistake-proofing device? b. Why is mistake proofing important in a cell's operation?
a. Assume that you are designing a machine cell for a product that has an expected life of one year. What would you automate? What would you not automate? b. If the product life is five years, what would you automate? What would you not automate? c. If the product life is 50 years, what would you
Why do cells use single-cycle automatic machines?
What is meant by manufacturing system design?
What should be the relationship between a manufacturing system and the enterprise system?
What are the six FRs of a stable manufacturing system? a. W. Edwards Deming said that to know when a problem exists we must distinguish normal from abnormal. How and why does standardized work make this idea possible? b. To achieve FRs, what must be added to make a system robust to variation? c.
Go to several fast-food restaurants and develop a value stream map of the operation. Determine whether each restaurant system design achieves the six FRs of system stability.
Repeat Question 6 for your college program. (You are the product receiving value adding knowledge via your courses.)
Why is it important for a system design to be robust?
What is standardized work? Why is standardized work necessary?
Assume that an assembly line produces three products, A, B, and C (see Figure 42-A). The available operating time per shift is 480 minutes. The cell operates two shifts per day. The average daily demand is 160 of A, 120 of B, 200 of C. What is the takt time?The assembly cell has the following
The Toyota Sewing System shown in Figure 42-9 does not have a worker covering the input and output stations.a. Is this a problem with the TSS?b. Suggest a fix for this problem.
If the first step is to form single-piece flow cells, what will be the consequence of all the hidden variations that existed in the job shop design?
Many companies build and customize their equipment. What are the advantages of this strategy? What are alternative strategies if a company lacks the technology to build their own equipment?
Give a detailed definition of a manufacturing system. Be sure to include all the elements of a manufacturing system.
List and define the functional requirements of the new integrated manufacturing system design, the lean shop.
What is the objective in manned Linked-Cell Manufacturing System Design? Describe the basis for maintaining this objective.
Define and give examples of internal elements and external elements of setup operations.
What are the advantages of integrated quality control? What is the fundamental difference between how quality control is implemented in a lean system and how quality control is implemented in other systems?
How is production control accomplished in lean manufacturing? How do the parts know where to go and how does the manufacturing system know when to make which part?
What is build-schedule stability for a vendor?
Name a pokayoke device that was built into your car.
How will you prepare the workforce to deal with the conversion to the lean shop?
If the cycle time for the paint cell is 60 seconds, how long will the painted parts in Figure 43-14 have to dry?
Who has the best ideas about how to improve work in the cells?
What common element exists in implementing both integrated quality control and integrated preventative maintenance?
Describe the difference between leveling and balancing.
Describe the difference between sequencing and synchronizing.
What is a Kanban system? Explain how it works in a manufacturing setting. Also, describe how the Kanban system can be used to lower inventory levels.
Try this exercise in SMED. Study how long it takes to change a tire on a car. What are the work elements of the current method? Did you videotape the changeover? Separate the elements into internal and external. Now study the tire change process again. How much time did you take out of the setup?
Prepare for class a three-minute presentation on one of the seven tools of quality control
The automobile has about 5,000 parts. How many parts does a typical mountain bike have? Which of these parts would be synchronized in delivery to final assembly?
A top-level manager at a manufacturing company just read a journal article on lean manufacturing and the Kanban system.
Figure CS-43 is a water pump impeller used by a major automotive parts manufacturer. The outer diameter of the component is 2.75 inches and the height is specified at 0.75 ± 0.005 inches. The I.D. of the center hole is 0.625 inches. The dimensions and positioning of the six blades is
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